Testing of a photovoltaic panel

ABSTRACT

A method for testing a photovoltaic panel connected to an electronic module. The electronic module has at least one input attached to the photovoltaic panel and at least one power output. The method of testing the photovoltaic panel begins with activating a bypass of the electronic module. The bypass is preferably activated by applying a magnetic or an electromagnetic field. The bypass provides a low impedance path between the input and output of the electronic module.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application benefits from U.S. applications 60/992,589 filed 5 Dec. 2007 and 61/039,050 filed 24 Mar. 2008 of the same inventors.

TECHNICAL FIELD

The present invention relates to production testing of photovoltaic panels, and more specifically to testing of photovoltaic panels which include integrated circuitry.

DESCRIPTION OF RELATED ART

Current voltage (IV) characteristics of a conventional photovoltaic panel are measured using a flash tester. The flash tester measures electrical current characteristics of a photovoltaic panel during a single flash of light of duration typically within one millisecond emitted by the flash lamp. The measurement procedure is based on known properties of a reference photovoltaic panel which has been independently calibrated in an external laboratory. The external laboratory has determined accurately the short circuit current corresponding to standard test conditions (STC) using an AM1.5G spectrum. AM1.5G approximates a standard spectrum of sunlight at the Earth's surface at sea level at high noon in a clear sky as 1000 W/m². “AM” stands for “air mass” radiation. The ‘G’ stands for “global” and includes both direct and diffuse radiation. The number “1.5” indicates that the length of the path of light through the atmosphere is 1.5 times that of the shorter path when the sun is directly overhead. During flash testing homogeneity of irradiance over the photovoltaic panel is obtained by a 6-meter distance between the flash lamp and the photovoltaic panel.

Reference is now made to FIG. 2 which illustrates a conventional flash tester 17. Flash tester includes a flash lamp 16, placed inside a closed lightproof cabin 19 which is painted black inside. Alternatively, black curtains minimize the intensity of reflections towards photovoltaic panel 10 from the interior surfaces of the cabin. The homogeneity of irradiance over area of photovoltaic panel 10 is measured by placing an irradiance sensor in various positions of the measurement plane. During the flash testing procedure, a flash tester 17 is connected to the output of photovoltaic panel 10. The measurement procedure starts with a flash test of a reference photovoltaic panel. The short circuit current is measured during an irradiance corresponding to AM1.5G. The reference photovoltaic panel is then exchanged for the test photovoltaic panel. During a subsequent flash, the irradiance sensor triggers a current-voltage (IV) measurement procedure at the same irradiance as during the measurement of the reference photovoltaic panel.

Conventional photovoltaic panels are typically connected together in series to form strings and the strings are optionally connected in parallel. The combined outputs of the connected photovoltaic panels are typically input to an inverter which converts the generated direct current voltage to alternating current of the grid. Recently, photovoltaic panels have been designed or proposed with integrated circuitry.

Reference is now made to FIG. 1 which illustrates schematically a photovoltaic system 14 with a circuit or electronic module 12 integrated with a photovoltaic panel 10. The term “electronic module” as used herein refers to electronic circuitry integrated at the output of the photovoltaic panel. The “electronic module” itself may be of the prior art or not of the prior art. A representative reference (Cascade DC-DC Converter Connection of Photovoltaic Modules, G. R. Walker and P. C. Sernia, Power Electronics Specialists Conference, 2002. (PESC02), Vol. 1 IEEE, Cairns, Australia, pp. 24-29) proposes use of DC-DC converters integrated with the photovoltaic panels. The DC-DC converter integrated with the photovoltaic panel is an example of an “electronic module”. Other examples of “electronic modules” include, but are not limited to, DC-AC inverters and other power conditioning electronics, as well as sensing and monitoring electronics.

Another reference of the present inventors which describes an example of photovoltaic system 14 including photovoltaic panel 10 integrated with electronic module 12 is US20080143188, entitled “Distributed Power Harvesting Systems Using DC Power Sources”.

The “electronic module” herein may have electrical functionality, for instance for improving the electrical conversion efficiency of photovoltaic system 14. Alternatively, “electronic module” as used herein may have another functionality unrelated to electrical performance. For instance in a co-pending patent application entitled, “Theft detection and Prevention in a Power Generation System”, the function of electronic module 12 is to protect photovoltaic system 12 from theft.

Since a standard flash test cannot typically be performed on panel 10 after integration with electronic module 12, for instance because the presence of module 12 affects the results of the standard test, it would be advantageous to have a system and method for flash testing of photovoltaic system

The term “photovoltaic panel” as used herein includes any of: one or more solar cells, cells of multiple semiconductor junctions, solar cells connected in different ways (e.g. serial, parallel, serial/parallel), of thin film and/or bulk material, and/or of different materials.

BRIEF SUMMARY

According to aspects of the present invention there are provided a method for flash testing a photovoltaic panel connected to an electronic module. The electronic module has at least one input attached to the photovoltaic panel and at least one power output. The method of flash testing the photovoltaic panel begins by activating a bypass of the electronic module. The bypass is activated by applying (preferably externally) a magnetic field or an electromagnetic field. The bypass provides a low impedance path between the input and output of the electronic module. The electronic module is typically permanently attached to the photovoltaic panel. The electronic module optionally performs DC to DC conversion or DC to AC conversion. The electronic module optionally performs maximum power point tracking at either the input or the output of the electronic module. The bypass circuit may include a reed switch, or a reed relay switch, a solid state switch or a fuse. After flash testing, the bypass of the electronic module is typically de-activated, by for instance communicating with the electronic module. The bypass may be permanently deactivated, or have an option for re-activation. Re-activation may be beneficial in such scenarios as electronics malfunction (such as disconnect), in which case re-activating the bypass will allow for connection of the photovoltaic panel directly to the output and continued power harvesting. According to aspects of the present invention there is provided a device for flash testing a photovoltaic panel connected to an electronic module. The electronic module has at least one input attached to the photovoltaic panel and at least one power output. A bypass provides a low impedance path between the input and output of the electronic module. The bypass includes a switch between the input and output of the electronic module. The switch may be a magnetically activated reed switch, an electromagnetically activated reed relay or a solid state switch. The electronic module may be, but is not limited to, a DC to DC converter, a DC to AC converter, or a maximum power point tracking module. The bypass includes a fuse and a parallel-connected switch. The parallel-connected switch is disposed between and connected in parallel with the photovoltaic panel and the electronic module. A power supply unit is connected across the output of the electronic module. The parallel-connected switch is closed to provide a low impedance path across the fuse to blow the fuse. The parallel-connected switch includes a silicon controlled rectifier, reed switch, solid state switch, or reed relay. Alternatively, a power supply is connected directly across said fuse and the current flow of the power supply de-activates the bypass by blowing of the fuse. The bypass may include a solid state switch. The bypass is deactivated either permanently (for instance in the case of a blown fuse) or the bypass may be reactivated as required (in the case of a switch.

According to still other aspects of the present invention there is provided a device for flash testing a photovoltaic panel connected to an electronic module. The electronic module has at least one input attached to the photovoltaic panel and at least one power output. A bypass applied to the electronic module has two single pole double throw (SPDT) switches and a single pole single throw (SPST) switch. The output node of the photovoltaic panel is connected to the first SPDT switch common. The first output node of the first SPDT is connected to the input node of the electronic module. The second output node of the first SPDT switch is connected to the input node of the SPST switch. The output node of the SPST switch is connected to a first input node of a second SPDT switch. The output node of the electronic module is connected to the second input node of the second SPDT switch. The output node of the second SPDT switch is connected to enclosure output which may be connected to the flash tester.

The foregoing and/or other aspects will become apparent from the following detailed description when considered in conjunction with the accompanying drawing figures.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention is herein described, by way of example only, with reference to the accompanying drawings, wherein:

FIG. 1 illustrates an electrical power generation system including a photovoltaic panel and electronic module.

FIG. 2 illustrates a flash test module of the prior art.

FIG. 3 illustrates a general equivalent circuit, representing the electronic module shown in FIGS. 1 and 2 with a bypass applied, according to a feature of the present invention.

FIG. 4 shows a flow chart of a method to flash test a photovoltaic panel according to an embodiment of the present invention.

FIG. 5 is an activated bypass circuit, according to an embodiment of the present invention, of an electronic module connected to a photovoltaic panel and test module.

FIG. 6 is a de-activated bypass circuit, according to an embodiment of the present invention of an electronic module connected to a photovoltaic panel.

FIG. 7 is an activated bypass circuit, according to another embodiment of the present invention, of an electronic module connected to a photovoltaic panel and test module.

FIG. 8 is a de-activated bypass circuit, according to another embodiment of the present invention of an electronic module connected to a photovoltaic panel.

FIG. 8 a is a de-activated bypass circuit using a fuse and power supply, according to another embodiment of the present invention of an electronic module connected to a photovoltaic panel.

FIG. 8 b is a de-activated bypass circuit using a fuse, power supply and silicone controlled rectifier (SCR), according to yet another embodiment of the present invention of an electronic module connected to a photovoltaic panel.

FIG. 9 is an activated bypass circuit, according to yet another embodiment of the present invention, of an electronic module connected to a photovoltaic panel and test module.

FIG. 10 is a de-activated bypass circuit, according to yet another embodiment of the present invention of an electronic module connected to a photovoltaic panel.

FIG. 11 illustrates yet another way in which to de-activate bypass once a flash test has been performed according to a feature of the present invention.

DETAILED DESCRIPTION

Reference will now be made in detail to embodiments of the present invention, examples of which are illustrated in the accompanying drawings; wherein like reference numerals refer to the like elements throughout. The embodiments are described below to explain the present invention by referring to the figures.

Reference is now made back to FIG. 1 which illustrates electrical power generation system 14, including photovoltaic panel 10 connected to electronic module 12. In some embodiments of the present invention, electronic module 12 is “permanently attached” to photovoltaic panel 10. In other embodiments of the present invention, electronic module is integrated with photovoltaic panel 10 but is not “permanently attached” to photovoltaic panel 10. The term “permanently attached” as used herein refers to a method or device for attachment such that physical removal or attempt thereof, e.g. of electronic module 12 from photovoltaic panel 10, would result in damage, e.g. to electronic module 12 and/or panel 10. Any mechanism known in the art for “permanently attaching” may be applied in different embodiments of the present invention. When electronic module 12 is permanently attached to the photovoltaic panel 10, the operation of photovoltaic panel 10 ceases or connections thereof are broken on attempting to remove electronic module 12 from photovoltaic panel 10. One such mechanism for permanently attaching uses a thermoset adhesive, e.g. epoxy based resin, and hardener.

Referring to FIG. 3, an example of electronic module 12 is illustrated in more detail. Electronic module 12 connects photovoltaic panel 10 and test module 20. Impedance Z1 is the series equivalent impedance of electronic module 12. Impedance Z2 is the equivalent input impedance of electronic module 12. Impedance Z3 is the equivalent output impedance of electronic module 12. Bypass link 40 when applied between the output of photovoltaic panel 10 and the input of test module 20 eliminates the effects of series equivalent impedance Z1 during a flash test. With bypass link 40 applied, impedances Z2 and Z3 are connected in parallel with resulting shunt impedance Z_(T) given in Eq. 1.

$\begin{matrix} {Z_{T} = \frac{Z\; 2 \times Z\; 3}{{Z\; 2} + {Z\; 3}}} & {{Eq}.\mspace{14mu} 1} \end{matrix}$ Where impedances Z2 and Z3 are both high in value, Z_(T) will have an insignificant effect upon a flash test of photovoltaic panel 10.

Reference is made to FIGS. 4, 5 and 6 which illustrate embodiments of the present invention. FIG. 4 illustrates a flowchart for a method for flash testing a photovoltaic panel 10 by bypassing an electronic module 12 according to embodiments of the present invention. FIGS. 5 and 6 are corresponding system drawings according to embodiments of the present invention of electrical power generation system 14. FIG. 5 illustrates bypass 40 when bypass 40 is activated. With reference to FIG. 5, a single pole single throw (SPST) switch 50 activated by magnetic field of magnet 52 connects the output of photovoltaic panel 10 and the input of test module 20 to bypass electronic module 12 during a flash test of photovoltaic panel 10. SPST switch 50 in an embodiment of the present invention is a reed switch (for example, Part no: HYR 2031-1, Aleph America Corporation NV USA) or a reed relay, or a solid state switch. Bypass 40 of electronic module 12 is activated (step 201) by applying a magnetic field 52 to SPST switch 50 causing SPST switch 50 to close as shown in FIG. 5. The flash test is performed (step 203) using flash test module 20. After the flash test of photovoltaic panel 10, bypass 40 of electronic module 12 is de-activated by the removal of magnetic field 52 to SPST switch 50 (step 205). FIG. 6 illustrates photovoltaic panel 10 connected to the input of electronic module 12, with SPST switch 50 bypass de-activated (step 205).

Reference is made to FIGS. 7 and 8 which illustrate another embodiment of the present invention. FIG. 7 illustrates bypass 40. With reference to FIG. 7, a fuse 50 a connects the output of photovoltaic panel 10 and the input of test module 20 to bypass electronic module 12 during a flash test of photovoltaic panel 10. Referring back to FIG. 4, bypass 40 of electronic module 12 is activated (step 201) by virtue of fuse 50 a being in an un-blown state as shown in FIG. 7 and SPST switch 5 b being open circuit. SPST switch 5 b in an embodiment of the present invention is a reed switch (for example, Part no: HYR 2031-1, Aleph America Corporation NV USA) or a reed relay, or a solid state switch. The flash test is performed (step 203) using flash test module 20. After the flash test of photovoltaic panel 10, bypass 40 of electronic module 12 is de-activated (step 205). FIG. 8 shows bypass 40 being de-activated (step 205). FIG. 8 shows photovoltaic panel 10 connected to the input of electronic module 12 and a power supply unit (PSU) 13 applied across the output of electronic module 12. SPST switch 5 b is in a closed position because of the application of magnetic field 52.

Reference now made to FIG. 11 which illustrates yet another way in which to de-activate bypass 40 (step 205) once a flash test has been performed (step 203) according to a feature of the present invention. Photovoltaic panel 10 is connected to the input of buck boost converter 12 a. The output of buck boost converter 12 a is connected to PSU 13. During deactivation of bypass 40 (step 205), a power line communication superimposed on the output of buck boost converter 12 a via PSU 13, a wireless signal applied in the vicinity of buck boost converter 12 a, or based on some logic circuitry—i.e. a specific supply voltage applied by PSU 13 causes MOSFETS G_(C) and G_(A) to turn on. MOSFETS G_(C) and G_(A) turned on causes a short circuit current I_(SC) to flow from PSU 13 and through fuse 50 a. The short circuit I_(SC) current blows fuse 50 a making fuse 50 a open circuit and bypass 40 is de-activated (step 205).

The closure of SPST switch 5 b and application of PSU 13 applied across the output of electronic module 12, causes a short circuit current I_(SC) to flow from PSU 13 through fuse 50 a and SPST switch 5 b. The short circuit I_(SC) current blows fuse 50 a making fuse 50 a open circuit and the removal of magnetic field 52 de-activates bypass 40 (step 205).

An alternative way of de-activating bypass 40 (step 205) is shown in FIG. 8 a. FIG. 8 a shows photovoltaic panel 10 connected to the input of electronic module 12 and a power supply unit (PSU) 13 applied across fuse 50 a. The application of PSU 13 across fuse 50 a, causes a short circuit current I_(SC) to flow from PSU 13 and through fuse 50 a. The short circuit I_(SC) current blows fuse 50 a making fuse 50 a open circuit and bypass 40 is de-activated (step 205).

Another way of de-activating bypass 40 (step 205) is shown in FIG. 8 b. FIG. 8 b shows photovoltaic panel 10 connected to the input of electronic module 12 and a power supply unit (PSU) 13 applied across the output of electronic module 12. The anode and cathode of a silicon controlled rectifier (SCR) 15 is connected in parallel across the output of photovoltaic panel 10 and the input of electronic module 12. The gate of an SCR 15 is connected inside electronic module 12 in such a way that the application of PSU 13 across the output of electronic module 12 causes a gate signal to be applied to the gate of SCR. A gate pulse applied to SCR 15 switches SCR 15 on. Alternative ways to get a pulse to the gate of SCR 15 include, power line communication superimposed on the output of electronic module 12 via PSU 13, a wireless signal applied in the vicinity of electronic module 12, or based on some logic circuitry—i.e. a specific supply voltage applied by PSU 13 causes a gate signal to be applied to SCR 15. A gate signal applied to SCR 15 and application of PSU 13 applied across the output of electronic module 12, causes a short circuit current I_(SC) to flow from PSU 13 through fuse 50 a and SCR 15. The short circuit I_(SC) current blows fuse 50 a making fuse 50 a open circuit and bypass 40 is de-activated (step 205).

Reference is now made to FIGS. 4, 9 and 10 which illustrate another embodiment of the present invention of electrical power generation system 14, particularly applicable in cases when the resulting shunt impedance Z_(T) is small enough to disrupt the results of the flash test, such as being less than 1 Mega Ohm in electronic module 12. Referring back to FIG. 4, FIG. 4 illustrates a flowchart for a method for flash testing a photovoltaic panel 10 by bypassing an electronic module 12 according to embodiments of the present invention. FIG. 4 includes step 201 of activating a bypass, step 203 performing the flash and de-activating the bypass, step 205.

FIG. 9 illustrates bypass 40 when bypass 40 is activated. With reference to FIG. 9, a single pole double throw (SPDT) switch 70, SPST switch 72 and SPDT switch 74, activated by magnetic field of magnet 52, connects the output of photovoltaic panel 10 and the input of test module 20 to perform the function of bypassing electronic module 12 during a flash test of photovoltaic panel 10. SPDT switches 70 and 74 in an embodiment of the present invention is a reed switch (for example, Part no: HYR-1555-form-C, Aleph America Corporation Reno, Nev. USA) or a reed relay, or a solid state switch. SPDT switches 70 and 74 when activated by magnetic field 52 provide open circuit impedance in place of shunt impedance Z_(T) when electronic module 12 is being bypassed during a flash test of photovoltaic panel 10. The bypass 40 of electronic module 12 is activated (step 201) by applying a magnetic field 52 to SPST switch 72 and SPDT switches 70 and 74 causing switch positions shown in FIG. 9. Next the flash test is performed (step 203) using flash test module 20. After the flash test of photovoltaic panel 10, the bypass of electronic module 12 is de-activated by the removal of magnetic field 52 to SPST switch 50 and SPDT switches 70 and 74 (step 205). FIG. 10 shows photovoltaic panel 10 connected to electronic module 12 with SPST switch 50 and SPDT switches 70 and 74 de-activated (step 205).

During operation of electrical power generation system 14, DC power is produced by photovoltaic panel 10 and transferred to the input of electronic module 12. Electronic module 12 is typically a buck-boost converter circuit to perform DC to DC conversion or an inverter converting DC to AC or a circuit performing maximum power point tracking (MPPT).

While the invention has been described with respect to a limited number of embodiments, it will be appreciated that many variations, modifications and other applications of the invention may be made. 

1. A device for testing a photovoltaic panel system including a photovoltaic panel having an output node and an electronic module, having an input node and an output node, the device comprising: a first single pole double throw switch, said first single pole double throw switch including an input common node, a first output node and a second output node; a first single pole single throw switch including an input node and an output node; a second single pole double throw switch, said second single pole double throw switch including an output common node, a first input node and a second input node; said output node of the photovoltaic panel connected to said input common node of said first single pole double throw switch; said first output node of said first single pole double throw switch connected to said input node of the electronic module; said second output node of said first single pole double throw switch connected to said input node of said first single pole single throw switch; said output node of said first single pole single throw switch connected to said first input node of said second single pole double throw switch; and said output node of said electronic module connected to said second input node of said second single pole double throw switch.
 2. The device of claim 1, wherein said first single pole single throw switch includes at least one member of a group consisting of: a magnetically activated reed switch; an electro-magnetically activated reed relay switch; and a solid state switch.
 3. The device of claim 1, wherein said electronic module is permanently attached to the photovoltaic panel.
 4. The device of claim 1, wherein said electronic module is configured to perform at least one of DC to DC conversion, DC to AC conversion, and maximum power point tracking.
 5. The device of claim 1, wherein said electronic module is configured to perform maximum power point tracking to maximize power on at least one of the input node of the electronic module and the output node of the electronic module. 